Disposable everything
Cleanup is a pain, especially if you're sensitive to the stronger chemicals such as
Methyl-Ethyl-Ketone. (aka MEK or Methyl-Eat-My-Carpet, this will even eat through
plastic tool handles if you leave them in there long enough. Don't splash, don't
get it on you. It's toxic. Don't breathe too much. It's also a carcinogen.) Cider
vinegar never worked well for me, so I shifted tacks. I now use butyl rubber gloves
to protect my hands, and to avoid having to clean them up I put latex gloves over
those. These can be reused several times if I'm careful to not splash epoxy all over
the place. I also:
Cutting Foam
I've tried a lot of techniques and they all have their advantages. I mark the foam
with a fine-point lead pencil (0.5mm), then cut to the outside of the line with a
coping saw, cleaning up the edge with sandpaper. Also, you can't see it in this
picture but I've made an edge-jointer out of a long, straight board and four
sheets end-to-end of 36-grit sandpaper. This puts a perfectly true edge on any
foam. Another trick is the Dozuki saw in the top of the picture, which makes very
straight lines. However, my favorite trick, with a better picture in the Chapter 4 details page, is to tap a wide razor blade
into the cut line with a hammer. This is my preferred method for straight lines
because I have arthritis, and it's easiest on my wrists. You can also make multiple
passes with the blade to gradually cut through, but as you get deeper, especially in
thick foams, this gets hard on the wrists/fingers.
Cutting Fabric
I've tried scissors and I've tried electric shears and both work well, the shears
doing a faster job, obviously. However, you have to lift the fabric to do this and
especially with BID, this distorts the fibers. A MUCH faster and better way is to
use a rotary cutter and a self-healing rubber cutting mat, as shown on the BID
piece in the picture below. The left edge was just cut with the rotary cutter. The
other three were cut with scissors. Do get the mat, though. If you do this on a
wood or hardboard surface it will get marred and the ruts will catch fibers as you
pull it out onto the table. That's worse than using scissors.